Apparatus for manufacturing floor mats



July I8, 1941.

D..F. COLLINS APPARATUS FOR MANUFACTURING FJOR MATS Original Filed Oct.i6, 1939 2 Sheets-Sheet 1 FBG INVENTOR.

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00N FREMONT BY ATTO July 8 1941. D. F. COLLINS- APPARATUS FORMANUFACTURING FLOOR MATS 2 Sheets-Sheet 2 Original Filed Oct. 16, 1939lllllll u. l

I N VEN TOR.

DON FREMONT COLLINS B r, /1 f /n Jef, l

ATTORNE s Patented July 8, 1941 APPARATUS FOR MANUFACTURING FLOOR MATSDon Fremont Collins, Pontiac, Mich., assigner to Baldwln"\RubberCompany, Pontiac, Mich... a corporation of Michigan Original applicationOctober 16, 1939, Serial No.

299,729. Divided and this application April 29, 1940, Serial No. 332,341

12 Claims.

This invention relates generally to apparatus for ymanufacturing iloorcoverings and is a division-ofjmy ycopending application Serial No. v-

z99,'z29,1ed=focmber 16, 1939; fMore. particularly, this inventionrefers to apparatusfor'naking composite floor matsof the "type v havinga covering sheetl of vulcanizable material and having a tread sheet ofpile fabric permanently secured to the top surface of thecovering-material with the piler extending up- 'vs'fardlyg f-Tothisfend,yone of the principal features of-'thisjinvention is to provideapparatus vforiiireforniing'both sheets to the contour of the floorsurface to be covered thereby and for securing the' sheets togetherwithout disturbing-or in- '-juring'the -pileon the tread sheet.

@Another object -of this invention' resides in the provision Vofapparatus having a form correspondingfin contour .to` the iioor vsurfaceto be covered `byftheinat and adapted to support the tionftothe treadsheet of pile fabric. -Inacc'ordancewith' this invention, the sheet ofpile fabric is supported in an inverted position with the pileext'endingvtoward the contoured surface ofthe form; and the covering sheet extendsover thetread sheet in engagement with the undersurface'of 'thefbase onthelatter sheet.

if StillI-another'cbiect of this invention resides der pressure isapplied to the exposed surface of the! covering'sheet to confonn bothsheets to yIn addition to the foregoing, the `present in"Y vention*'contemplates apparatus embodying meansfor introducing fluidunderpressure en the pileside ofthe fabric sheet and controllingthispressure to'such an extent that'it is sumcient to'prevent 'nettingof the pile under the actioncofthe heated fluid under pressure but atthewsfameftime does notinterfere with the pile assuming the contour ofthe form.

"'-Theforegoing as wellas other objects, will be made more apparent asthis description proceeds, especially, when considered in connectionwith the'accompanying drawings, wherein--A Figure 1 jis a perspectiveview of a section of a'vehicle body flooring covered by a composite matconstructed with the apparatus forming the subject matter of thisinvention; v'.*igureZ' is a sectional view taken substantiallysheet-ofvulcanizable'covering material in relaon the plane -indicated bythe line 2-'2 of Figure 1;

Figure -3 is a plan view of 'a contoured form and illustrating a matsupported on the top surface thereof;

Figure 4 is a sectional view taken substantially on the plane indicatedby the line 4-4 of Figure 3; v

Figure 5 is a diagrammatic view illustrating the. differential pressurecontrolled valve;

Figure 6 is a sectional view throughthe valve.

In Figures 1 and v2 of the drawings. I have illustrated amat fashionedin accordance with this invention-and 'applied to a floor section ofaavehicle body having a hump intermediate the opposite side edges toprovide clearance for certain parts of the vehicle driving mechanism.

The mat is preformedto the contour of the sur-- 25 Upon reference toFigure 2, it will be noted tread sheet II of Pile fabric permanentlysecured to the covering sheet with the pile I4 extending upwardly. VInthe present instance, the covering sheet ill is formed of a vulcanizablematerial and is cured to the contour of the particular floor surface tobe covered thereby. Although the tread`sheet II is flexible,nevertheless, it is also subjected to the curing operation and in thismanner is likewise preformed to the surface contour of the flooring andthis is accomplished without injuring or matting thepile. In theillustrated embodiment of the invention, the tread sheet of pile fabricII is in the form 40 of an insert and. is positioned in a recess l2sheet of pile fabric is vulcanized to the base I3 formed in the coveringsheet I0 during the curing process. It will, of course, lbeunderstoodthat the sheet of pile fabric is located in the recess I2 withthe undersurface of the base `I3 engaging 45 the bottom surface I5 ofthe recess and a bead- I6 is formed on the covering material in a mannerto surround the tread sheet of pile fabric. As will' be presently setforth, the portion of the covering sheet I0 extending over the |base I3of the tread or with an adhesive material which will become A that theportions of the covering material Il are body by means of a backingmaterial il'. The

will now be made to the apparatus employed for making 'the mat.r Thisapparatus not only description proceeds.

umetai plate It having an upwardly extending marginal flange 2,4 forminga pocket Il., ge

` faceof the rubber 'sheet' I1 of the mat when the latter is positionedon thegcontour'ed surface of the form. It may Ii around the tread sheetof pile fabric.

2,248,743 tacky under the temperatures employedduring the vulcanizingoperation.

v tread sheet Il. `Referring again to Figure 2. it will be observed 'Theair -is tiren exhausted from the chamber 2l through themedium of'asuitable vacuum pump (not shown) communicating with the interior of thechamber Il by means of a conduit 2l As a result, any air trapped betweenthe properly supported from the flooring I1 of the' 5 backing materialIl' is preferably formed of asbestos. iiocl: or Jute and surrounds therecessed l portion .il ofithe mat. although. if desired,l the of theform ise'xhausted through the clearance backing may alsov be extendedbeneath the bot- 10 22' and a vacuum seal is enected around the tom'surface of the recessed portion Il. marginal edges of the stock. Inother words, Having ibriefly described thev mat, reference the stockisdrawn tightly against the adjacent surface of the form and this isdesirable in that it insures curing the covering sheet Il totherendersit possible to cheaply form the mat to 15' exact surface contourof the form. the contour of the surface of the flooring to be Thecontoured form is then placed into a prescovered by the mat but alsopermits permanentsure chamber, designated generally in Figure 4 lysecuring' the tread sheet of pile fabric to the 'by the referencecharacter il, and fluid prescovering sheet during the curing operationwithsure is admitted to the chamber through the out matting orotherwiseiniuring the pile on the j medium of a supply conduit il. Thefluid under tread sheet. The appaiano is shown more psp. menne actsuvon'the exposed surface .of the ticularly in Figures 3 to 6. inclusive.and coml prises a form Iliprefashioned to correspond in the arrows inFigure 4. and is preheated to the contour to the iiobr surface to becovered bythe vtemperature required to cure the stock to the mat. Uponreference to Figure 4, it will be contour of the form.notedthattheformhasabeseplateitcovered j Ithaspreviously beenpointed outthat the by a sheet of hard rubberl material 2l which, in tread sheet ofpile fabric is permanently secured turn,4 is suitably secured to the topsurface of the, to the covering sheet Il during the interval the plate.The marginal portions of the plateil ex" lattersheet is curedto thecontour of the form.

tend laterally beyond the'marginal edges of the 4'30j This may beaccomplished in several different ways, One method which has been foundsatiscovering material 2l and are return bent to form factory'is toapply a rubber o r curing cement to a chamber 2| around the border ofthe covering material 2I. The top wall 22 of the chamber 2| overlaps thetop surface 4of the hard rubber eovsheet so that 'during the curingoperation. the

'eringvsheet 2l and, in turn,.is,adapted tc be over- "85 pile fabricsheet is vulcaniiiedv to the covering lapped by the marginal edgeportions of the sheet. Another method of accomplishing this result is tocoat the undersurface of the base Il on the fabric tread sheet with anadhesive or a further be pointed out at this time that a 'cieairibituminous binder which will become tacky durancell' exists between theflange f2 and` the '40 ing the curing operation and cause the base ontop surface of the form Il; v'l'he purpose of this the pile fabric toadhere to the covering sheet construction will be made more apparentesthis il. t

, In orderto prevent the force of; the p .It will,also be noted fromFigure 4 that `i-.he acting upon theportion of the stock extendingportionof the top surface of the form il ccrreover the pocket Il frommatting or otherwise spondingtotheareaofthematoccupiedbytheiniuringthepilellonthefahrictreadsheetli. treadsheetof pilefabric Ilis'covered byasheet provision ismade herein for introducing s positive'counteracting pressure in the pocket Il. Thepressure built upin thepocket Il is accu*- pocket flhasadepth approximatingthe f ness of .thepilefabric sheet il and is adapted than the curing medium pressureapplied to the to receive the pile is on the treadsheet when exposedsurface oftheccverlns sheet Il so that the latteris supported in theinverted position both sheds mayfollow the contour of thesurshowninrflguretltmaybepointedoutat faceoftheform.Howeventhepressurebiult this time that in the present embodimentlof theA55 up in the pocket Il is suilcient'to prevent colinvention. a recess 2lis formed in, the top surlansing 0f the Pol'n 0f the met extending overcovering sheet 2l and extends the pocket and thereby also preventsmatting of continuously around the marginal flange 24 of the pocket. Asbe more fully hereinafter set forth. the recess It receives the adjacentpord0 tions of the covering sheet and forms the bead pressure is suchthat ,the Dile' is retainedin its natural state throughout the curingoperation and a mat is attained which not only neatly conforms totheirregularities' in the surface of the nooring but which alsopossesses a'very neat, pleasing appearance.

The fluid under pressure is admittedv tothe pocket 2l practically at thesaine time that the pressure of *the curing medium is applied to thestock and is accurately controlled by a valve assembly l2. Uponreference to Figure 6, it will be noted that the valve assembly 82comprises a valve casing 33 divided into two chambers 34 The-above'construction is suchas .to permit, .the tread sheet of pile fabric tobe positioned in the pocket 2s with the pile extending ccwn- 5 wardlyand with the bottom surface of the base It lying substantially flushwith the top edges or side walls .[24 of the pocket. After the treadsheet of pile fabric is properly positioned in the 7n pocket 25, a sheetof uncured rubber stock. or similar vulcanlzable material is placed overthe form il with the marginal edges thereof over-y anw" by meansv of admphmm The up lapping the BnSeS 22 wd'wih the central p0rper chamber i4communicates with the interior tion extending' over the pocket 251mcontact 75 of the pressure chamber 3l through the medium with'theundersurface of the base it on the A 'sheet of uncured stock and theadjacent surface covering sheet Il in-themanner indicated by,

the undersurfsce of the base It on the pile fabric1 60 lteli continuedInd ll preferably slightly les! the pile against the adjacent surface ofthe form. In other words, the positivedifferential l 2,a'4s,74s

of a conduit 31 so that the pressure in the cham- A ber 34 is the sameas the pressure acting upon the -rubber stock during the vulcanizlngprocess.

lof a valve 40.

Referring' again to Figure 6, it will be noted that .the supply line 39communicates with a municates'with av second chamber 42 separated fromthe chamber 4| by means of a web 43 having an opening 44 therethroughestablishing communication between the two chambers. 'Ihe end of thepassage 48 in the valve stem 4-5. As a result, communication between.the supply line 39 and exhaust conduit 52 is closed. Upon continueddownward movement of the central portion of the diaphragm 36, the valve53 lifts thel valve 40 against the action of the spring 41 and openscommunication between the supply line 39 and the deuvery conduit as.Accordiiigw, fluid 10 chamber 4| and the distributing line 36 com-'xunder pressure from the source of supply iiows through the deliveryconduit 38 into the ppcket 25 and into the chamber 35 below the'diaphragm 36. The fluid pressure admitted to the chamber 35 counteractsthe'pressure of the curing meopening 44 is controlled bythe valve 40having a y valve stem 45 extending through the opening 44 and havinganenlarged portion 46 on the stem normally urged into seating engagementwith the opening 44 by means of a spring 41. The lower portion lof thestem is axially bored to provide a passage 48 terminatingat a pointbelow the enlargement 46 and communicating with the interior of thechamber 42 by means of a transverse passage 49.. The lower end of thepassage 48 communicates with still another chamber 56 separated from thechamber 42 by means of a web 5| having a central opening therethroughforming a guide for the valve stem 45. The chamber 50 communicates withthe atmosphere through the medium of an exhaust conduit 52 andcommunication between the chamber 42 and the chamber 50 is controlled bymeans of a valve 53. lihe valve 53 is supported for sliding movement inthe direction of the valve stem 45 and the upper end thereof is adaptedto control the lower end of the passage 48 through the valve stem 45.

The valve 53 is operated by the diaphragm 36 through the medium of anactuating arm 54 having one end pivotally connected to the centralportion of the'diaphragm, as at 55, and having the opposite endpivotally connected to the slide valve 53, as at 56. i, The arm 54 isfulcrumed inhaving the marginal rtions xedly secured and forming a sealfor th chamber 35. The central portion of the diaphragm 36 is normallyurged in an upward direction against the stops 56 to termediate theendsga flexible diaphragm 51 a position wherein the exhaust valve 53 isopen by means of a spring 59 having the lower end connected to thecentral portion of the diaphragm and having the upper end secured to anut 6|!-V which, in turn, is threaded on an adjusting Operation of thedierential pressure controlled valve The differential pressurecontrolled valve 32 is shown in Figure 6 in its inoperative positionwherein the valve 40 is closed to prevent the supply of iiuid pressureto the pocket 25 and whereinthe exhaust' valve 53 is open .to providefor exhausting the pocket 25 through the passage 48 lin the valve stem45. However, as soon as the curing mediumpressure is admitted into thepressure chamber through the medium of the supply pipe 3|, this fluidmedium flows through the conduit 31 intoA the upper chamber 34 of thedium in the chamber 34 and tends to move the central portion of thediaphragm in an upward direction to again open the exhaust valve 53.This force of the fluid pressure ifthe chamber 35 is assisted by thespring 59, with. he result that the pressure inthe chamber 35 and in thepocket 25 is maintained below the rpressure inthe chambers 30 and 34. Itfollows, therefore, that the pressure in the vulcanizing chamber 30 isat all times balanced against the sum of the spring tension and thedifferential pressure inthe pocket 25. In other words-the differencebetween the pressure of the curing medium in the vulcanizng chamber 30and the pressure in the pocket 25 is a constant equal to the tension ofthe spring 59 which is adjustable to provide for varying the pressuredifferential.

When the curing operation is completed and the pressure supply line 3|is closed by a suitable valve (not shown), the pressure in the chamber35 will, of course, predominate.' As a result, the central portion ofthediaphragm 36 is moved upwardly and the valve 53 is moved downwardly bythe arm 54 to not onl'yopen the `exhaust passage 48, but to also permitthe spring 41 to close the differential pressure supply line 39.

Thus from the foregoing, it will be observed that I have provided arelatively simple apparatus for manufacturing composite mats of the typeillustrated herein at a'nominal cost and at a;l rate suitable for highproduction methods. It will also be observed that the'apparatuspreviously described renders it possible to preform the mats so that thelatter will accurately conform to contoured oor surfaces and impart apleasing appearance to the latter.

What I claim as my invention is:

1. 'In apparatus for making iioor coverings, a form adapted to support acovering. sheet of vulcanizable stock and a sheet of pile fabric 'withthe undersurface of the base portion of the fabric contacting theadjacent surface of the stock and withlthe pile extending toward theform, means for applying a iiuid under pressure on the 'exposed face ofthe stock to urge both the latter and pile fabric toward the form, andmeans for applying an opposing fluid under pressure on the Dile side ofthe fabric sheet to prevent matting of the pile against the form underthe pressure of said rst mentioned means.

2. In apparatus for making floor coverings, a.

posed face of the stock to urge both the latter,

and pile fabric toward the form, means for applying an Opposing iiuidunder pressure on the moved upwardly by the arm 54 to close the lower 75pile side of the fabric sheet to prevent matting of the pile against theform under the pressure of .said first mentioned means, and means conuidbeing sumcient to cure the stock to the controlling the fluidunderpressure exerted on the tour of the form and to secure the 'stockto the pile side of the fabric sheet and effective to mainsheet of pilefabric, means applying an opposing tain a predetermined v dinerentlalbetween said fluid under pressure against the pile side of the pressureswith a preponderance of pressure act- 5 fabric sheet, and control 'meansfor the opposing ing on the exposed face of the stock.' fluidunderpressure operable to maintain this 3. In apparatus formakingcontoured :floor pressure at a value predetermined to prevent coverings,a form having -a contoured surface matting of the pile against the formand at the adapted to support a coveringsheet of vulcanizsame time topermit the sheets to follow the conable stock and a sheet -vof pilefabric with the baserr 1 0 tour of the form. i i of the latter.contacting the stock and with the 7. In apparatus for making contouredfloor pile extending toward the contoured surface -of coverings, a formhaving `a contoured surface the form, ,means for applying a preheatedfluid adapted t0 Support a lcovering Sheet 01 vulcanmedium` underpressure to the exposed face of izable Steek 81nd 8 Sheet 0f Dile fabricwith the the stock to Aurge the. latter toward the con- 15 base portionof the latter contacting the stock toured surface of the form and tocure the stock and with the pile extending toward the contoured to thecontour of the form, means applying an surface of the form, means forapplying a. fluid opposing uid under pressure. against the pile underpressure against ,the exposed face of the side of thefabric sheetandcontrol means for stock-to urge the latter into intimate contact theopposing fluid under Vpressure operable t0i20 With the base DOrtion ofthe Dile fabric andto maintain this pressure at a value predeterminedconform both sheets to the contoured surface of to prevent matting ofthe pile against the form the form. means applying anopposing fluidunand at the same time to'permit the sheets to foider pressureagainst-the pile side of the fabric low the conto'ur of -the form underthe influence Sheet t0 Prevent matting 0f the pile against the of thefluid under pressure exerted by the pre-` 2 5 adjacent surface of theform, and means for cur heated fluid medium, ing the stock to thecontour of the form and for 4. In apparatus for making floor coverings,a securing thestock to the base of the pile fabric form adapted tosupport a covering sheet of vul- Sheetcanizable material and a sheet ofpile fabric with 8. In apparatus for making composite mets. n the baseportion of the pile fabric contacting the! 30 fOrm having a surfaceadapted to support a sheet covering sheet and with the piie Jextendingtcof stock and having e pocket interrupting said wardthe form, saidforin having a chamber into Surface, said pocket adapted to be coveredbythe which the pile` extends, means for applying fluid Sheet. 0f Steekund being 0f Suilleient Size to reunder pressure on the exposed face ofthe cov.. CeiVe 8' Sheet 0f material t0 be Secured t0 Sd ering sheet tourge the latter and pile fabric.'3,5 Steek. Ineens for applying a fluidunder pressure sheet lin a direction toward the form, and means On'theexposed surface of the stock vto rge the for introducing an opposingfluid under pressure latter toward the surface aforesaid of the form, insaid chamber to prevent the pile on the fabric and' means forintroducing fluid under pressure sheet from matting against the adjacentsurface into said pocket to oppose the pressure 'applied of the form, l1,40 by the flrst named means against the portion of 5. In apparatus formaking floor coverings for the Steek extending over the pocket. A' noorsurfaces having a hump therein. a form. 9- In apparatus for makingcomposite mats, a

having a surface provided withfa recess correform having a surfaceadapted to support a. sheet spending in dimension and shape to the hump,of Stock and having meansextending above the said `formadap'ted tosupport a sheet or vuicaniz 4;, Surface forming a pocketI ofpredetermined aree. able stock and a sheet of pile fabric with the S815DOClIet adapted t0 be GOVeI'ed by the Sheet 0f base portion of the pilefabric contacting the stock and being of suillcient size to receive apile Stock and with the pue extending toward the fabric'with the base ofthe fabric facing the surform, both sheets extending over the recess inlfelicev 0f the Steek extending over the pocket. the surface aforesaidof the form, means for ap-i 50 means for applying fluid under pressureto the explying' fluid under pressure t0 the exposed face posed surfaceof the stock to urge the latter to-. of the stock to urge the latter andsheet of pile Ward the surface aforesaid of the form, means for fabrictoward` the form, means for introducingy introducing fluid UnderPressure into Said pocket i an opposing fluid under pressure againstthe. pile t0 ODPOSe the Pressure applied by ythe rSt named 51de of thefabric sheet, mnh-01 means far` the` 55 means 4against thel portion ofthe stock extending @poging mud under pressur operable to mamoverl thepocket. and means for controlling the tam this pressure at a, valuepredetermined to counteracting pressures and effective tomaintainprevent matting of the pile against'the form and the Pressure in thepocket suiflciently high to at the same time to permit the sheets toconform Prevent mntting'of the Pile 883111815 tbe dinoenii to thecontour of said surface of the form,and. 60 Surface of the form bytheopposing pressure. means for curing the stock to the contour of the 10In apparatus I01' making composite mais. form. a form having acontouredsurface adapted to 6. In apparatus for making contoured nocisupport asheet of vuleenizable Stock end'haviniry coverings, a form having acontoured `surface n DOCket in Sad Surfeeeem Docket adapted to adaptedto Support a @vering sheet f vulcan-, 65 be covered by the sheet ofstock and also adapted izable stock and a sheet ofl pile fabric with thet0 receive n Sheet 0f Dile fblie with the base of base portion of the19M-,er contacting the stock the fabric facing the surface of thestockcextendand with the pile 4extending towgrd the. coning over thepocket, means for exhausting air i toured surface. of the form, meansfor applying from the joint between the adjacent surfaces of `apreheated iluid'medium under pressure to thev 7o the-form andstek,.means fOr applying a Pre- 'exposed face ofthe stock to urge the lattertoheated fluid under pressure on the exposed surward the contouredsurface of the form into inface of the stock to,vulcanize the latter tothe timate contacting relation with the base portion contour of theform, and means for introducing cr the pile fabric sheet and to conformboth.; fiuid under pressurenuto the pockit to oppose sheets to thecontour or the form, the heat ot tiie- 75 the pressure applied on theexposed surface ici ama-743 the stock extending over the pocket andthereby resist matting of the pile by the latter pressure.

-11. In apparatus for making composite mats, a form having a surfaceadapted to support a sheet of stock and having a pocket in said surface,said pocket adapted to be covered by the sheet of stock and adapted toreceive a sheet of material to be secured to the stock with one face ofthe material in contact with the surface of the stock extending overthepocket, means for subjecting the exposed-surface of the sheet ofstock to the action of fluid under pressure to urge the stock in adirection toward-the form, means for introducing a counteracting fluidpressure in the pocket, and a valve controlling the flow of fluid underpressure to the pocket and eiective to maintain a predetermineddifferential between the counteracting pressures with a preponderance ofpressure acting upon the exposed surface ofthe stock.

12. In apparatus for making composite mats, a pressure chamber, a formsupported in the pressure chamber and having a surface adapted tosupport a sheet of stock, a pocket interrupting the surface of the formand adapted to receive a sheet of material with one surface of thematerial contacting the surface of the stock extending over the pocket,means for introducing uid under pressure into the pressure chamber tourge the stock against the contoured surface of the fo'rm, means forintroducing fluid under pressure into the pocket at the side of thesheet of material opposite the side engaged with the stock, adifferential pressure controlled valve having a casing divided into twochambers by a diaphragm and having one chamber communicating with thepressure chamber aforesaid, means establishing communication between theother valve and the pocket, and means responsive to the action of thediaphragm under the influence of the differential pressures on oppositesides of the diaphragm to 20 control the pressure of the fluid in saidpocket.

DON FREMONT COLLINS.

